Shoe and method of manufacture

ABSTRACT

A shoe, and method of manufacture, including (i) a shoe upper having an arrangement of holes in the bottom surface, (ii) an outer sole having an arrangement of holes corresponding to the arrangement of holes in the bottom surface of the shoe upper, and (iii) an inner sole disposed within the shoe upper, the inner sole having a plurality of pegs that extend from its bottom surface that are arranged in alignment with the arrangement of holes in the shoe upper and outer sole when the inner sole is disposed within the shoe upper, each peg extending downwardly through its associated hole in the shoe upper and the outer sole, so that, in the preferred embodiment, the bottom surface of each peg is exposed to, and forms part of, bottom surface of the shoe.

The present invention relates to a new and improved shoe and a novelmethod of manufacture that is more efficient, less costly and safer thanthe prior art.

BACKGROUND OF THE INVENTION

Shoe manufacturers strive to produce products that are comfortable,lightweight, sturdy, durable, shock absorbent and breathable, yetinexpensive. Incorporating all of these characteristics in a singleshoe, however, has been difficult to achieve without employingmanufacturing techniques that are expensive, labor intensive andtime-consuming, and which sometimes employ hazardous manufacturingmaterials and methods, such as the use of glues or sealants, which mayproduce toxic fumes and which require time-consuming cooling duringmanufacture.

Simpler manufacturing techniques, such as those employed in themanufacture of “flip-flops” (an example of which is disclosed inpublication number US 2009/0044423 to Amsterdam) result in reducedmanufacturing costs but do not produce a “shoe,” as opposed to a simplebeach sandal or the like, which has limited durability and practicaluse.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to produce arelatively high-quality shoe and a novel method of manufacture that ismore efficient, less costly and safer than the prior art.

Briefly, the shoe produced in accordance with the preferred embodimentof the present invention includes a shoe upper having an arrangement ofholes in the bottom surface, an outer sole having an arrangement ofholes corresponding to the arrangement of holes in the bottom surface ofthe shoe upper, and an inner sole disposed within the shoe upper, theinner sole having a plurality of pegs that extend from its bottomsurface that are arranged in concentric alignment with the arrangementof holes in the shoe upper and outer sole when the inner sole isdisposed within the shoe upper. In accordance with the preferredembodiment, each peg extends downwardly through its associated hole inthe shoe upper and the outer sole, so that the bottom surface of eachpeg is exposed to the bottom surface of the shoe. Preferably, the bottomsurface of each peg is substantially coplanar with the bottom surface ofthe outer sole. Alternatively, a supplemental outer sole, made from amaterial similar to the material of the outer sole, may be applied tothe bottom surface of the outer sole, if desired.

In accordance with the preferred embodiment, the outer sole and innersole, including the pegs, are formed of resilient, deformable material.Each peg is configured substantially in the shape of an inverted “T”,and each hole in the outer sole contains a recess that is configured toclosely accommodate the configuration of each peg, so that each peg fitssnugly within its associated recess. Preferably, each peg and itsassociated recess have substantially circular cross sections, but othercross sections, such as square, for example, may be used as well.

Various materials preferred for the shoe upper, the inner sole and theouter sole are disclosed, and the materials can be chosen so that thesole, formed by the outer sole and the pegs, can have a substantiallyuniform surface. The outer sole may be die-cut or molded.

The method for manufacturing a shoe in accordance with the preferredembodiment of the present invention includes the steps of inserting aninner sole having a plurality of pegs extending from its bottom surfaceinto a shoe upper having an arrangement of holes in its bottom surfacecorresponding to the arrangement of the pegs, inserting each of theplurality of pegs through its corresponding hole on the bottom surfaceof the shoe upper, providing an outer sole having an arrangement ofholes corresponding to the arrangement of holes in the bottom surface ofthe shoe upper, and inserting each of the plurality of pegs through acorresponding hole in the outer sole, wherein after inserting each ofthe plurality of pegs through a corresponding hole in the outer sole,the bottom surface of each peg is exposed to and forms part of thebottom surface of the shoe, and preferably is substantially coplanarwith the bottom surface of the outer sole. Alternatively, the method mayalso include the step of applying a supplemental outer sole to thebottom surface of the outer sole.

The resulting manufacture is a shoe that is comfortable, lightweight,sturdy, durable, shock absorbent and breathable, and which is producedusing a manufacturing technique that is efficient, inexpensive, and doesnot require the use of toxic glues or sealants, resulting in productionthat is safer, more consistent, and which does not require a cooldownprocess. The resulting flexible inner sole/foot bed is shock absorbent,lightweight and comfortable and may be made of many different kinds ofmaterials. The shoe produced in accordance with the present inventioncan employ an upper of any conventional style and have an appropriatepull strength to accommodate multiple activities and durability.

These and other objects and aspects of the present invention will bemore fully described in accordance with the following detaileddescription.

DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C are perspective views of the inner sole, upper and outersole in accordance with the preferred embodiment of the presentinvention;

FIGS. 2A-2D are perspective views of the preferred embodiment of thepresent invention showing the construction of the shoe, and the methodof manufacture, in accordance with the present invention;

FIGS. 3A-3D show cross-sections taken through FIGS. 2A-2D, respectively;

FIGS. 4A-4B illustrate details of the overall construction of the shoein accordance with the preferred embodiment of the present invention, inperspective and in cross-section, respectively;

FIG. 4C illustrates an alternative peg;

FIGS. 5A-5F illustrate alternative forms of the inner sole of thepresent invention;

FIGS. 6A-6C illustrate shoes made in accordance with the presentinvention having different styles of uppers;

FIGS. 7A-7E illustrate a manufacturing technique for assembling theshoes in accordance with the present invention;

FIGS. 8A-8B illustrate an alternative construction for the shoe inaccordance with the present invention; and

FIG. 9 illustrates another alternative peg.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIGS. 1A-1C, a shoe in accordance with the preferredembodiment of the present invention is manufactured with three basiccomponents: an inner sole 20, an upper 30 and an outer sole 40. Theinner sole 20 is provided with pegs or protrusions 22 extendingdownwardly from the bottom surface of the inner sole. The upper 30 isprovided with a corresponding set of holes 32, and outer sole 40 isprovided with a corresponding set of holes 42. As shown in the figures,the pegs 22, holes 32 and holes 42 are configured to be in concentricalignment, and the holes 32 and 42 extend completely through the upper30 and outer sole 40 respectively. In the preferred embodiment, theupper 30, inner sole 20 and outer sole 40 are substantially co-extensiveand substantially cover the entire sole, although separate heel andforefoot structures could be employed, if desired. The outer sole has awidth that extends from a medial sidewall of the shoe to a lateralsidewall of the shoe.

The particular arrangement of the pegs 22, and corresponding holes 32and 42, can be as illustrated generally in the drawings, but variationscan be made by those skilled in the art to accommodate different stylesand sizes so that they can readily accommodate men, women and children,for different activities, as desired, and to avoid placing the pegs atflex and stress points, as may be necessary or desired.

The structure and method of construction of the shoe in accordance withthe present invention are illustrated in connection with FIGS. 2A-2D and3A-3D. The inner sole 20, shown in FIGS. 2A and 3A, is placed inside ofupper 30, and the pegs 22 are inserted through each of theircorresponding holes 32 in the upper 30, thereby resulting in theconfiguration shown in FIGS. 2C and 3C. The holes 32 in the upper 30 maybe reinforced with an embroidery-like stitch around the edges of eachhole, similar to dress shirt buttonholes. Such reinforcements canalternatively be of other conventional construction such as aheat-embossed plastic reinforcement rings, or other constructions thatwill be apparent to those skilled in the art. The shoe is finallyassembled by inserting the pegs 22 through their corresponding holes 42in the outer sole 40. As described below, one or more of the inner sole,outer sole and upper may be formed of resilient, deformable material, tothereby facilitate the insertion of the pegs 22 through the holes 32 and42. The final assembly is shown in perspective in FIG. 4A and incross-section in FIG. 4B. As best shown in FIG. 4B, and in accordancewith the preferred embodiment of the invention, the bottom surface ofeach peg 22 is exposed to and forms part of the bottom surface of theshoe, and preferably, the bottom surface of each peg is substantiallycoplanar with the bottom surface of the outer sole 40, to produce asubstantially uniform surface. It will be appreciated that the term“substantially co-planar” would encompass the shoe generally shown inFIG. 4B even if minor variations in the surface are employed, resultingfrom tread patterns or the like, or for example, an indentation in peg22 a shown in FIG. 9 for the insertion of a company logo or other mark.

In the preferred embodiment, each peg 22 is substantially cylindrical,having a circular cross-section, although other cross sections, such assquare (an example of which is shown as peg 22′ in FIG. 4C), may be usedas desired. Each peg is generally configured in the shape of an inverted“T”, although angular variations in the “T” shape (e.g., a slanted(italic) “T”) are within the scope of the term “substantially inverted‘T’ shape”. Each hole 42 in the outer sole contains a recess on thebottom surface of the outer sole that is configured to closelyaccommodate the configuration of the peg 22, so that each peg fitssnuggly within its associated recess. The use of resilient materials forone or more of the inner sole and outer sole will facilitate the snugfit between the pegs 22 and the recesses 42.

It will be appreciated that no glues or sealants are required in theconstruction of the preferred embodiment of the shoe, which is verybeneficial, as described herein. Furthermore, and as explained in moredetail below, the construction of the shoe, using the upper 30, innersole 20 and outer sole 40 as shown in the figures, results in a shoethat can be manufactured very quickly and efficiently.

FIGS. 5A-5F show variations of the inner sole 20 which may be employed,if desired. For example, as shown in FIG. 5A, inner sole 20 can havecupped end portions 23 to accommodate different uppers, or for betterfit or comfort. Similarly, as shown in FIG. 5B, inner sole 20 can beprovided with a contoured edge 24 for better fit, comfort or toaccommodate different uppers. As shown in FIG. 5C, and its associatedcross-section FIG. 5D, the inner sole 20 can be provided with an archsupport region 25. FIG. 5E illustrates a version of the inner sole 20that has supportive contours and reflexology-inspired massage beads 26.Finally, FIG. 5F shows the use of perforated knockout holes 27 which mayextend through the entire thickness of the inner sole 22 and provide foradded breathability and lighter weight.

FIGS. 6A-C illustrate different uppers that can be made in accordancewith the present invention. In particular, FIG. 6A illustrates a loafer34, FIG. 6B illustrates a slipper 35, and FIG. 6C illustrates an Oxford36. Additional styles of shoes can be used, as desired.

FIGS. 7A-7E illustrate a preferred method of manufacture of the shoe inaccordance with the present invention. In particular, after pegs 22 areinserted through their associated holes in the bottom of the shoe upper(as described in connection with FIGS. 2A-2C), a tool 50, havinggripping jaws 52, is inserted through the bottom side of hole 42 inouter sole 40, as shown in FIG. 7A. The gripping jaws 52 of the tool 50open and grip the associated peg 22, as shown in FIG. 7B. The peg isthen pulled through the hole 42 in the outer sole 40, as shown in FIGS.7C and 7D, and then the tool is released, as shown in FIG. 7E. Theprocess is repeated for each of the pegs 22 of the inner sole 20, untilthe shoe is completed. It will be appreciated that the foregoing methodcan be automated or implemented manually.

The foregoing construction and assembly is efficient and inexpensive,and can be used advantageously even if a supplemental outer sole,covering the bottom surfaces of the pegs and of the outer sole, isemployed. With reference to FIGS. 8A-8B, supplemental outer sole 60,which should be durable, and preferably made of a material the same asor similar to the material selected for the out sole 40, may, ifdesired, be applied to the bottom surfaces of the pegs and of the outersole through the use of a standard glue or sealant.

It will be appreciated that all of the foregoing constructions result ina shoe that is comfortable, lightweight, sturdy, durable, shockabsorbent and breathable. It is produced using a manufacturing techniquethat is efficient, inexpensive, and, in the preferred embodiment, doesnot require the use of glues or sealants. The materials required toproduce the shoe have been reduced and the amount of labor similarlyreduced to thereby significantly shorten the production line process.Although glue or a sealant may be used to bind one or more of the threecomponents to each other, such is not required in the assembly process,and thus production is safer, more consistent, does not require acooldown process, and cuts down on highly toxic fumes, creating a betterwork environment.

The shoe produced in accordance with the present invention can employ afootwear upper of any conventional style and have an appropriate pullstrength to accommodate multiple activities and durability. The innersole/foot bed is shock absorbent, lightweight and comfortable.

Because of the efficiency in manufacturing, and minimal labor, thepresent invention drastically reduces production costs and increasesquality. Furthermore, the shoe made in accordance with the presentinvention may be made of many different kinds of durable materials andwill be lightweight and slip resistant. Exemplary materials for theupper include canvas, denim, leather, mesh, neoprene, polyurethane,suede, nubuck, cotton, woven mesh, polyurethane, and synthetic leather;exemplary materials for the inner sole include, rubber, thermoplasticrubbers, ethylene-vinyl acetate, blown ethylene-vinyl acetate, injectedmolded foam, injection molded rubber, plastic, and polyurethane; andexemplary materials for the outer sole (and supplemental outer sole, ifdesired), which can be die-cut or molded, include ethylene-vinylacetate, thermoplastic rubbers, thermoplastic elastomers, blownethylene-vinyl acetate, blown rubber, leather, injected molded foam, andinjection molded rubber. Because the inner and outer soles can be madefrom the same or similar materials, it will be appreciated that thecompleted shoe can have a sole, formed by the outer sole and the pegs,that has substantially uniform characteristics throughout its extent. Itshould be noted that the foregoing materials are exemplary, and othermaterials may be selected by those skilled in the art to accomplish thegoals of the invention set forth herein.

The foregoing preferred embodiments described herein are set forth asexemplary, and it will be appreciated that various modifications may bemade without departing from the scope and spirit of the invention whichis defined by the following claims.

I claim:
 1. A shoe comprising: a shoe upper having a first plurality ofholes in a bottom surface of the shoe upper; an outer sole having asecond plurality of holes corresponding to the first plurality of holes;and an inner sole configured to be disposed within the shoe upper, theinner sole having a plurality of pegs extending from a bottom surface ofthe inner sole and arranged to concentrically align with the firstplurality of holes and the second plurality of holes when the inner soleis disposed within the shoe upper, each peg extending downwardly into arespective one of the first plurality of holes and a respective one ofthe second plurality of holes, wherein a bottom surface of each pegforms part of a bottom surface of the shoe.
 2. The shoe of claim 1,wherein the bottom surface of each peg is substantially co-planar with abottom surface of the outer sole.
 3. The shoe of claim 1, wherein eachpeg is configured in a substantially inverted ‘T’ shape, and each holein the outer sole contains a on a bottom surface of the outer solerecess that is configured to receive a respective peg of the pluralityof pegs, wherein each respective peg fits snuggly within said respectiverecess.
 4. The shoe of claim 3 wherein said pegs and said recesses havea substantially circular cross-section.
 5. The shoe of claim 3 whereinsaid pegs and said recesses have a substantially square cross-section.6. The shoe of claim 3 wherein the upper, the inner sole and outer soleare substantially co-extensive.
 7. The shoe of claim 1 wherein the outersole has a width that extends from a medial sidewall of the shoe to alateral sidewall of the shoe.
 8. The shoe of claim 1 wherein the upperis comprised of a material selected from the group consisting of:canvas, denim, leather, mesh, neoprene, polyurethane, suede, nubuck,cotton, woven mesh, and synthetic leather.
 9. The shoe of claim 1wherein the inner sole is resilient and is formed of a material selectedfrom the group consisting of: rubber, thermoplastic rubbers,ethylene-vinyl acetate, blown ethylene-vinyl acetate, injected moldedfoam, injection molded rubber, plastic, and polyurethane.
 10. The shoeof claim 9 wherein the inner sole has at least one of the structuresselected from the group consisting of; (i) cupped end portions, (ii) acontoured edge, (iii) an arch support region, (iv) massage beads, or (v)perforated knockout holes.
 11. The shoe of claim 1 wherein the outersole is resilient and is formed of a material selected from the groupconsisting of: ethylene-vinyl acetate, thermoplastic rubbers,thermoplastic elastomers, blown ethylene-vinyl acetate, blown rubber,leather, injected molded foam, and injection molded rubber.
 12. The shoeof claim 11 wherein the outer sole is die-cut.
 13. The shoe of claim 11wherein the outer sole is molded.
 14. A shoe comprising: a shoe upperhaving a first plurality of holes in a bottom surface of the shoe upper;an outer sole having a second plurality of holes extending completelythrough the outer sole, the second plurality of holes corresponding tothe first plurality of holes; an inner sole configured to be disposedwithin the shoe upper, the inner sole having a plurality of pegsextending from a bottom surface of the inner sole and arranged toconcentrically align with the first plurality of holes and the secondplurality of holes when the inner sole is disposed within the shoeupper, each peg extending downwardly into a respective one of the firstplurality of holes and a respective one of the second plurality ofholes; and a supplemental outer sole applied to, and in contact with, abottom surface of the outer sole and respective bottom surfaces of theplurality of pegs.
 15. The shoe of claim 14, wherein each peg isconfigured in a substantially inverted ‘T’ shape, and each hole in theouter sole contains a recess on the bottom surface of the outer solethat is configured to receive a respective peg of the plurality of pegs,wherein each respective peg fits snuggly within said respective recess.16. The shoe of claim 15 wherein the upper, the inner sole and outersole are substantially co-extensive.
 17. The shoe of claim 15 whereinthe inner sole is resilient and is formed of a material selected fromthe group consisting of: rubber, thermoplastic rubbers, ethylene-vinylacetate, blown ethylene-vinyl acetate, injected molded foam, injectionmolded rubber, plastic, and polyurethane.
 18. The shoe of claim 15wherein the outer sole is resilient and is formed of a material selectedfrom the group consisting of: ethylene-vinyl acetate, thermoplasticrubbers, thermoplastic elastomers, blown ethylene-vinyl acetate, blownrubber, leather, injected molded foam, and injection molded rubber. 19.The shoe of claim 18 wherein the supplemental outer sole is comprised ofthe same material as the outer sole.
 20. A shoe comprising: a shoe upperhaving a first plurality of holes in a bottom surface of the shoe upper;an outer sole having a second plurality of holes extending completelythrough the outer sole, the second plurality of holes corresponding tothe first plurality of holes, the outer sole having a width that extendsfrom a medial sidewall of the shoe to a lateral sidewall of the shoe; aninner sole configured to be disposed within the shoe upper, the innersole having a plurality of pegs extending from a bottom surface of theinner sole and arranged to concentrically align with the first pluralityof holes and the second plurality of holes when the inner sole isdisposed within the shoe upper, each peg extending downwardly into arespective one of the first plurality of holes and a respective one ofthe second plurality of holes; and a supplemental outer sole applied toa bottom surface of the outer sole.